Form for molding openings in concrete structures



Nov. 10, 1953 Filed June 28. 1950 A. c. AVRIL 2,658,252

h FORM FOR MOLDING OPENINGS m CONCRETE STRUCTURES 2 Sheets-Sheet l 15 IZ7 Z6 Z0 5 l .18, 14 15 g ICIII ZLZIII 7:22:2

.4? INVENTOR.

BY 'Ldov-nl (la-1 II 'v/ ATTORNEYS.

A. C. AVRIL Nov. 10, 1953 FORM FORMOLDING OPENINGS IN CONCRETESTRUCTURES Filed June 28, 1950 2 Sheets-Sheet 2 2 z 4 C, IN V E N-TOR.

ATTORNEYS.

Patented Nov. 10, 1953 FORM FOR MOLDING OPENINGS IN CONCRETE STRUCTURESArthur C. Avril, Cincinnati, Ohio, assignor to A and T DevelopmentCorporation, St. Bernard, Ohio, a corporation of Ohio Application June28, 1950, Serial No. 170,760

3 Claims.

This invention relates to the erection of monolithic concrete buildingsand resides in a form structure for blocking out various openings inwalls, panels, slabs and the like during erection, particularly the doorand window openings of the building. The walls and panels of a buildingof this class ar constructed by pouring a wet concrete mix in spacedforms which delineate the inner and outer wall surfaces and the presentform structure consists of sectional units which are assembledcollectively to delineate the sides of the opening formed in the wall.These units are designated in this disclosure as breach forms todistinguish them from the wall forms with which they cooperate.

The breach forms are installed between the spaced wall forms and providea temporary dam corresponding in size and shape to the desired opening,serving to exclude the wet concrete mix from the delineated area. Afterthe poured concrete is set, the Wall and breach forms are removed,leaving in the wall an opening to receive a standard door or windowframe which is later installed permanently in the opening, following theusual practice.

The present structure is intended particularly for use in erectingbuilding walls according to the method disclosed in my co-pendingapplication, entitled Method and Apparatus for Erecting ConcreteStructures, Serial No. 85,748, filed April 6, 1949. This co-pendingapplication discloses a method of erecting buildings by the progressiveerection of relatively shallow wall forms which are clamped inhorizontal courses upon opposite sides of preset vertical guide columnsso as to embed the columns in the wall when the wet concrete is pouredand tamped into the spaced forms. In practicing this method each courseof wall forms preferably is poured and tamped individually; in otherwords, one course of forms is installed and poured, then the next courseis installed upon the first and poured and tamped so as to homogenizethe courses of concrete. The procedure of installing and pouring formcourses is continued until the full wall height is reached and the wallforms are removed when the concrete is set and are used also in forminga concrete roof slab upon the building.

The present breach forms constitute sectional units corresponding insize and shape to the wall section and are interposed between the spacedwall forms as the forms are erected one upon another, the breach formsbeing arranged to seat one upon another in the same manner as the wallforms. If it is desired to form openings in the roof slab, the breachforms are applied in the same manner upon the forms which support theroof slab.

In defining a window opening, the wall forms are successively installedand poured until the height of the opening is reached and at this pointa breach form unit is placed between them. As succeeding form coursesare erected, successive breach forms are inserted one upon another tooutline the opposite sides of the window opening. The same procedure isfollowed in forming door openings and other openings except that thebreach forms are started at the bottom of the Wall for door openings.

Each breach form consists essentially of a pair of dam platescorresponding to the cross section of the wall and a spacer bar whichhas its opposite ends in bearing engagement against the spaced damplates. The spacer bar holds the plates rigidly in position to resistthe hydrostatic pressure developed by the tamped concrete and isconveniently detached to permit removal of the dam plates from theopening after the concrete has set.

A primary object of the invention has been to provide a sectional formunit adapted to cooperate with the sectional wall forms and permit theprogressive erection of walls having door and window openings inaccordance with the procedure disclosed in the above noted co-pendingapplication.

Further objects of the invention have been to provide form units whichmay be installed and removed in .a rapid and convenient manner withoutchipping the corners of the opening; to provide an assembly which isadjustable to accommodate openings suitable for the various standarddoor and window frame sizes; and to provide sectional units which arcapable of being joined edge-to-edge to form an opening of accurate sizehaving straight, smooth surfaces.

A In order to provide ready installation and removal of the breach formunits, the spacer bar which maintains the spacing between the dam or endplates, has its opposite ends detachably engaged within sockets mountedupon the inner surface of the plates. These sockets permit the bar .tobe installed by slipping its opposite ends downwardly into the open endsof the sockets and removed by lifting the bar upwardly to free the damplates after the concrete has set. The adjustability of the opening sizeis provided by utilizing a telescopic tubular spacer bar which isprovided with selective apertures such that the telescopic sections maybe lengthened with respect to one another to change the spacing betweenthe dam plates. The tubes are locked in adjusted position by slipping ataper pin through the matching apertures of th adjusted bars. Theapertures preferably are arranged in respective sets in the telescopicsections, one set being spaced to provide variations in multiples of onefoot, and the second set spaced to provide multiples of one inch,whereby the required opening width may conveniently be selected. Inaddition, a screw threaded connection is established between one sectionof the spacer bar and the corresponding dam plate whereby a fineadjustment of the spacing can be achieved by rotating the bar withrespect to the plate. This adjustment permits the individual form unitsto be adjusted precisely in alignment with one another to providesmooth, flush surfaces between adjoining plates in assembly.

As disclosed in the preferred embodiment of the invention, the insideand outside wall forms are provided respectively with horizontalrecesses and V-shaped channels to provide a decorative wall contour, andin order to prevent leakage of the wet concrete mix between theinterface of the wall and breach forms, the side edges of the dam platesare configurated to interfit in nesting engagement with these surfaces.In order to stiffen the forms, the side edges which interfit the wallforms are provided with angular flanges which intimately embrace thesurface of the wall forms. The upper and lower edges of the dam platesalso are provided with stiffening flanges which provide seats wherebythe respective courses of dam plate units may be mounted one uponanother for the successive installation of them. These flanges areprovided with matching apertures for the reception of anchorage screwsfor securing the superposed dam plates to one another in assembly.

Various other features and advantages of the invention will be morefully apparent to those skilled in the art from the following detaileddescription taken in conjunction with the drawings.

In the drawings:

Figure 1 is a fragmentary side elevation of a poured concrete wallsection as viewed from the outside with wall forms removed, showing adoor and window opening blocked out by the improved breach form units,the form units being shown in position in the window opening.

Figure 2 is a view similar to Figure 1 showing the wall forms installedduring the course of construction, with the breach forms mounted betweencourses of spaced wall forms.

Figure 3 is an enlarged fragmentary cross sectional view taken on theline 33 of Figure 2, showing the interfitting relationship of the breachfor-ms with the wall forms.

Figure 4 is a longitudinal sectional view taken on the line 44 of Figure3, further detailing the relationship between the breach and wall forms.

Figure 5 is an enlarged inside face view of the dam plate of one of thebreach forms as viewed in Figure 3.

Figure 6 is an enlarged sectional view taken on the line 66 of Figure 5,detailing one of the dam plates and the end of the spacer bar inassociated relationship with its socket.

Figure 7 is a sectional view taken on the line 1--1 of Figure 5illustrating the manner of de- As best disclosed in Figures 2 and 4, thebreach form units, indicated generally at I0, are applied between thespaced inside and outside wall forms, indicated respectively at I2 andI3, during the course of erection. After placement of the breach form,the wall forms are clamped against the opposite sides of the precastvertical columns I4. The spaced wall forms are held in clampedengagement against the vertical columns by means of the wall ties I5which are clinched as at I6 over the meeting flanges I! of the wallforms. The concrete preferably is cast in single courses afterinstallation of each course of wall and corresponding breach forms, andfollowing the casting and tamping of a given course, the next course offorms is installed and the procedure repeated successively for the fullheight of the wall.

In the preferred mode of operation, the walls are divided into bayswhich are delineated by the vertical columns I4 (Figures 1 and 2), andthe wall forms are of sectional construction to permit the span betweenthe columns to be varied longitudinally. Thus, both the inside andoutside wall forms I2 and I3 are made up of end sections I8I8 joined byan intermediate section 20 which overlies the inner portion of the endsections, permitting the end sections to be butted up against the innersurface of the columns I4.

In one preferred form structure, by way of illustration, the individualwall forms are twelve inches high and the closure or dam plates 2| ofthe breach forms are the same height, the side edges of the plates beingconfigurated to nest with the contour of the wall forms. As bestillustrated in Figure 3, the inner edge of the plate is recessed as at22 to conform to the longitudinal recess or trough 22a of wall form I2.The outside edge of plate 2| is provided with angular corners 2323corresponding to the V- shaped configuration 23a of the outside wallform I3.

The sets of dam plates 2I delineate the opposite vertical sides of theopening and are held in spaced relationship by respective telescopicspacers indicated generally at 24, one for each set of plates. Thespacers span the opening to support the opposed dam plates against thehydrostatic pressure of the wet concrete mix, the opposite ends of eachspacer being supported in sockets indicated generally at 25. Each spacerbar constitutes a tubular section 26 telescopically engaged within atubular section 21 having an inside diameter suitable to establish asliding fit with the section 26 (Figure 4). In order to permit theOpening sizes to be varied, the tube section 26 is provided with aseries of apertures 28 and the section 21 is provided with a secondseries of apertures 29 arranged to register with the openings 28 topermit the insertion of a taper pin 30 (Figure 5) for locking thesections with respect to one another at the desired spacing. In thepresent example, the apertures 28 may be spaced twelve inches apart andthe apertures 29 one inch apart to permit the adjustment in multiples offeet and inches. In addition, a very fine adjustment may be effected byrotating the tube section 21 with respect to the nut 3| which is weldedto the channel 32 which engages the retainer socket 25.

The sockets 25 each consist of a pair of angle plates 3333 welded as at34 to the dam plate 2|, thus providing overhanging flanges 35-35 adaptedto overlie the side flanges 36-38 of taching the spacer bar from thespacer socket. the channels 32 which are attached respectively antennato the opposite ends of the spacer bars. As viewed in Figure 4, theright hand channel 32 is welded as at 31 directly to the end of the tubesection 26, while the channel for the left hand end is welded as at 38to the nut (Figure 6).

Each dam plate is provided with a pair of horizontal flanges 33- 39along its upper and lower edges, and vertical flanges 48-40 along itsopposite side edges. As viewed in Figure 3, the vertical flanges bearagainst the surface of the inner and outer wall forms, and thehorizontal flanges 39 of adjoining dam plates rest upon one another tosupport the superposed plates. In addition, these flanges reenforce thedam plate against distortion under the hydrostatic pressure imposed uponthem by the'tamped concrete. As shown in Figures 3 and 6, the flanges 39include matching apertures 4l--4| adapted to receive screws 42 forclamping the flanges firmly together in assembled relationship.

In constructing a wall requiring a door opening, as shown in Figure 1,the breach form units are placed in position starting with the firstcourse of forms, preferably with the spacers 2- 4 in position and lockedin adjustment. As best shown in Figures 5 and 7, there is provided a web44 extending crosswise of the socket, the web being welded in positionto support the spacer bar assembly relative to the plates 2!. After thewall forms are installed and clinched by the Wall ties, the concrete iscast and tamped firmly between the spaced wall forms, as shown in Figure4. The next breach form unit is then placed in position upon the first,and clamped by the screws 42, following which the next course of wallforms is installed and poured. This operation is continued until the topof the opening is reached, at which point a header plate 45 is placedacross the top 'of the dam plates to delineate the top of the opening.As shown in Figure 1, the header, which is shown in the window opening,constitutes a flat plate having side flanges 45 for stiffening purposesand preferably includes apertures matching the apertures 4| of the damplates to permit it to be bolted in place. In forming a window opening,the procedure is the same as for the door opening, except that thebreach forms are not installed until the wall reaches an elevation abovethe floor corresponding to the desired elevation of the window opening.The spacers 24, by virtue of the apertures 28 and 29, are arranged todelineate window and door openings for the several standard frame sizes,the opening size being selected by applying the taper pin to the propermatching apertures as above outlined.

In fabricating the wall, the courses of concrete are poured and tampedpreferably while the next lower course is still in plastic condition, sothat the successive courses will knit firmly together. After the lowercourses have set permanently, the wall and breach forms may be removedand re-used for the succeeding courses, thus, reducing the number offorms required for a given job. After removal of the wall forms, thebreach forms are removed by knocking the spacers upwardly to dislodgethem from their sockets, as indicated in Figure 7, then removing thescrews 42. The individual dam plates can then be removed easily from theopening leaving a smooth surface for installation of the door and windowframes in the customary fashion.

Although the improved structure is intended expressly for use with thesectional forms of the type disclosed in the co-pending application, itis contemplated also to use them with standard forms in substantiallythe same manner by changing, if necessary, the edge configuration of theplates to correspond with the forms. .Also, the use of the plates is notnecessarily limited to the construction of walls, but they may beapplied substantially in the same manner tothe construction of concreteroof and floor slabs which require openings. By virtue of theadjustability provided by the nuts 3|, the dam plates in assembly can beadjusted accurately in vertical alignment with respect to one another to.form a straight, smooth surface which is devoid of undesirableirregularities and which'is extremely accurate as to size and shape.

Large openings for garage doors and the like can be formed by usingspacer bars of increased length, following the same technique followedfor the smaller openings. Thus, the same basic unit is capable offorming almost any type of opening, simply by adjusting the requirednumber of units to correspond to the width and stacking them one uponanother for the required height. Since the forces imposed upon the damplates are resisted in compression by the spacers, no additional bracingis needed for larger openings.

The dam plates preferably are oiled to prevent bonding to the concrete;thus, after the spacers are removed, the plates can be easily pulledaway from the sides of the opening without danger of chipping thecorners. Exceptionally sharp, clean corners are produced by the closefit between the side edges of the dam plates and the inner surface ofthe wall forms.

The opening can be formed with flush sides, or if desired, the inneredge of the opening can be recessed to interfit the sides of the door orwindow frame by attaching a demountable recess former to the face of thebulkhead or closure plates. The structure for forming the flush sides isillustrated in Figures 1 to 3 inclusive,'and in Figures 4 to 7 theclosure plates are provided with face plates 41 which are secured bycountersunk screws 48 to the face of the closure plate. As shown mostclearly in Figure 6, the face plate is shaped along one side to form avertically disposed channel portion 50, and along its opposite side toform an angular lip 54, The channel 50 molds an inset recess in the sideof the opening along the inside wall surface and thus presents anabutment 50a (Figure 4) for engagement by the window frame when it 'isinserted in the opening. Also, as shown in Figure 4, the lip chamfersthe corner of the opening along the opposite side of the wall.

The header 45 may be removed from its position across the opening whenthe closure plates are removed but it is preferable to cast it in as apermanent part of the opening to improve the appearance of the opening.The permanent header preferably is formed from aluminum to eliminatecorrosion and discoloration of the wall surface. As disclosed in Figure1, the header 45 of the window opening is greater in length than thewidth of the opening, with its opposite ends embedded in the wall as at52. The header may be keyed to the wall by the provision of bolts, lugsor the like extending upwardly and adapted to be embedded in theconcrete above the header. The header can be made removable simply by (6cutting it to the width of the opening so that 7 its ends rest upon theclosure plates but do not become embedded in the concrete.

In order to provide a rigid support for the header of exceptionally wideopenings, the standard breach form units consisting of closure platesand spacers can be placed end to end in horizontal courses one uponanother with the closure plates resting one upon another. The stackedplates thus provide a series of columns supporting the header atintermediate points to prevent sag. The opening thus is rigidly bracedin both directions against the pressure developed by the wet tampedconcrete.

Having described my invention, I claim:

1. In a form structure for molding poured concrete walls and the likeconstituting spaced sets 01' substantially continuous horizontal innerand outer wall forms adapted to delineate the inner and outer wallsurfaces, a dam structure adapted to delineate an opening at a selectedposition in the poured wall comprising, a pair of closure membersconstructed and arranged to be mounted in spaced relationship with oneanother between the spaced inner and outer wall forms to provideclosures between the wall forms and thereby to delineate the sides of anopening in the wall, a spacer element adapted to be interposed betweenthe closure members to maintain the members in spaced relationship withone another, the closure members being adapted to slidably contact thespaced inner and outer wall forms and to resist the pressure of thepoured concrete independently of the wall forms, the spacer elementconstituting a pair of bars telescopically interfitted with one another,each bar having a plurality of spaced apertures, the apertures of threspective bars being adapted selectively to register with one anotherupon lengthwise adjustment of the bars, a pin adapted to be insertedthrough the registering apertures to lock the said bars at adjustedlength relative to one another, and a fine adjustment element interposedbetween at least one of the spacer bars and its associated closuremember and in screwthreaded engagement with the spacer bar, the fineadjustment element being constructed and arranged to vary the spacingbetween the closure members upon rotation of the spacer bar relative tothe closure member.

2. In a form structure for molding poured concrete walls and the likeconstituting spaced sets of substantially continuous inner and outerwall forms adapted to delineate the inner and outer wall surfaces, a damstructure adapted to delineate an opening at a selected position in thewall comprising, a pair of closure plates constructed and arranged to beinterposed in spaced relationship with one another between the spacedinner and outer wall forms to provide closures between the wall formsand thereby to delineate an opening in the poured wall, a spacer baradapted to be interposed between the spaced closure plates to maintainthe plates in spaced relationship with one another, said closure platesbeing adapted to slidably contact the inner and outer wall forms and toresist the pressure of the concrete poured between the inner and outerwall forms, a spacer bar retainer mounted on each of said closure platesadapted to support the respective ends of the spacer bar, the spacer barretainers each constituting a pair of angle members spaced from oneanother and secured to the closure plate to stiffen the same, the spacedangle members being arranged to form a socket having an open end, and arespective locking member secured upon the opposite ends of the spacerbar adapted to be detachably inserted in the open end of the socket toprovide a detachable engagement therewith.

3. In a form structure for molding poured concrete walls and the likeconstituting spaced sets of substantially continuous horizontal innerand outer wall forms adapted to delineate the inner and outer wallsurfaces, a dam structure adapted to delineate an opening at a selectedposition in the wall comprising, a pair of closure plates constructedand arranged to be interposed in spaced relationship with one anotherbetween the spaced inner and outer wall forms to provide closuresbetween the wall forms and thereby to delineate an opening in the pouredwall, a spacer bar adapted to be interposed between the said plates tomaintain the plates in spaced relationship with one another, saidclosure plates being adapted to slidably contact the said inner andouter wall forms and to resist the hydrostatic pressure developed by thewet concrete mix independently of the inner and outer wall forms, aspacer bar retainer mounted on each of said closure plates adapted tosupport the respective ends of the spacer bar, the retainers eachconstituting a pair of angle members spaced from one another and securedto the closure plate to stiffen the same and providing opposed flangessubstantially parallel with and spaced from the closure plate, theadjacent inner edges of the said flanges being spaced from one anotherto receive th end of the spacer bar therebetween, and respective channelmembers secured upon the opposite ends of the spacer bar, the channelmembers being adapted to be inserted between the said angle members withthe opposed flanges overlying the channel members thereby providing adetachable connection between the spacer bar and closure plates.

ARTHUR C. AVRIL.

References Cited in the file of this patent UNITED STATES PATENTS NumberName Date 543,056 Rue July 23, 1895 938,010 Merriett Oct, 26, 19091,231,462 Tutwiler June 26, 1917 1,40 ,898 Farness Dec, 27, 1921 1,63,846 Penote June 21, 1927

